Floor Sanding Device, Floor Treatment Plate and Method for Sanding a Floor

ABSTRACT

The present invention relates to a floor sanding device for sanding a floor. The invention further relates to a floor treatment plate and a method for sanding a floor. The floor sanding device comprises: —a carrier plate and a drive for driving the carrier plate; —a treatment plate for treating a surface of a floor, wherein the treatment plate is operatively coupled to the carrier plate; and —an intermediary plate that is arranged between the carrier plate and the treatment plate, wherein the intermediary plate comprises at least one compartment for receiving at least one pressure member for providing a higher local pressure.

The present invention relates to a floor sanding device for sanding a floor. The invention further relates to a floor treatment plate and a method for sanding a floor.

Floor sanding devices are known from practice, wherein the floor sanding devices are configured to sand a floor, for example a wooden floor. The known floor sanding devices generally comprise a carrier plate on which a treatment plate can be operatively coupled. The carrier plate is operatively coupled to a motor that drives the carrier plate. Because of the operative coupling of the treatment plate to the carrier plate the movement from the carrier plate will be translated to the treatment plate. The treatment plate will then sand the floor.

As the carrier plate is made of a rigid material, for example metal, the pressure of the floor sanding device is substantially directly transferred to the treatment plate and thus onto the floor. This has as its disadvantage that because of the rigidity the floor sanding device is hard to control. A further disadvantage of conventional devices is that when the floor treatment plate comes into contact with an irregularity in the floor, there is a high chance of damage to the floor, such as a breaking off pieces of the floor, irregular sanding scratches or sanding lanes.

To alleviate these disadvantages it is known for some conventional devices to place a flexible plate between the carrier plate and the treatment plate. Because the flexible plate is made of a flexible material, for example foam rubber, the floor sanding device can more easily follow the irregularities on the floor. A disadvantage of providing a flexible plate between the carrier plate and the treatment plate is that an insufficient sanding pressure can be provided to the floor, resulting in a loss of productivity. A further disadvantage of using a flexible plate is that, due to the increased generation of heat, parts of the treatment plate can be glazed, which reduces the effectiveness of the floor sanding device.

It is an object of the present invention to obviate or at least reduce the abovementioned problems of the known floor sanding devices. It is in particular an object of the present invention to provide a floor sanding device which reduces the chance of damage to the floor while maintaining sufficient sanding pressure.

The object of the present invention is achieved by a floor sanding device, wherein the floor sanding device comprises:

-   -   a carrier plate and a drive for driving the carrier plate;     -   a treatment plate for treating a surface of a floor, wherein the         treatment plate is operatively coupled to the carrier plate; and     -   an intermediary plate that is arranged between the carrier plate         and the treatment plate,     -   wherein the intermediary plate comprises at least one         compartment for receiving at least one pressure member for         providing a higher local pressure.

Due to the compartment being configured to receive at least one pressure member for providing a higher local pressure the sanding pressure is transferred more directly to the floor at the location of the pressure member. This achieves a productive sanding of the floor. As the intermediary plate transfers a lower sanding pressure than the pressure member, the floor sanding device is able to follow the irregularities on the floor. This has as its advantage that the risk of damaging the floor, such as irregular sanding scratches, is reduced. In this way the floor sanding device according to the invention reduces the risk of damage on the floor, while at the same time providing sufficient sanding pressure to sand the floor effectively.

The carrier plate is preferably made of a rigid material, for example metal. The carrier plate is operatively coupled to a drive such that the carrier plate acquires a sanding movement, for example a lateral or circular translation in a plane parallel to the floor. Due to the rigid material of the carrier plate the pressure of the floor sanding device can be effectively transferred through the intermediary plate into the treatment plate.

The term treatment plate may also refer to an abrasive fleece, and in the present invention these two terms can be read interchangeably. The treatment plate is configured to be applied on the floor for sanding the floor. The treatment plate comprises sanding grains for effectively sanding the floor. In general the floor to be sanded would be a wooden floor.

It is noted that the present invention is not limited to the shape of either the carrier plate, intermediary plate and/or treatment plate. Examples of possible shapes are disc-shaped, rectangular-shaped and triangular-shaped. It will be understood that also other shapes can be envisaged in accordance with the invention.

In an embodiment according to the invention the floor sanding device further comprises at least one pressure member that is configured for placement in the at least one compartment, wherein the stiffness of the at least one pressure member is higher than the stiffness of the intermediary plate.

In the context of the invention stiffness is defined as the amount of force necessary to deform an object or material. The stiffness of an object or material can be expressed in the Young's modulus of the object or material. The higher the Young's modulus, the higher the force needed to deform an object. In the present invention stiffness can also be denoted as hardness, in particular indentation hardness. The hardness of an object or material can be expressed in Shore hardness. Preferably the Shore A scale is used, which can be measured with a Shore A durometer. The higher the Shore hardness, the higher the force needed to deform an object. For elastomers, the relationship between the Young's modulus E and the Shore type A hardness S is for example:

$E = {\frac{0.0981\left( {56 + {7.62336S}} \right)}{0.137505\left( {254 - {2.54S}} \right)}.}$

Due to the stiffness of the pressure member being higher than the stiffness of the intermediary plate the intermediary plate will deform more easily when it moves over irregularities on the floor. This means that the sanding pressure provided to the floor by the treatment plate is higher at the location of the pressure members than at the location of the intermediary plate. This has as its advantage that the floor can be effectively stranded at the location of the pressure members as seen in a direction substantially perpendicular to the floor. A further advantage is that at location of the intermediary plate irregularities on the floor are more easily followed, thereby increasing the handling of the floor sanding device and the chance on damage of the floor is reduced.

In an embodiment according to the invention the at least one pressure member is removably provided in the at least one compartment.

By removably providing the at least one pressure member in the compartment the pressure members can be easily exchanged. This is for example advantageous when the pressure member is broken or lost its stiffness and needs to be replaced. Another advantage is that the pressure members can be exchanged for pressure members with a different stiffness. This increases the flexibility of the floor sanding device, as the sanding pressure can be adjusted by choosing different pressure members. Alternatively or additionally the pressure members can be of the same stiffness as the intermediary plate, thereby achieving a floor sanding device which is also able to polish the floor. Another advantage of the pressure members being removably provided is that when the pressure members are removed, the floor sanding device can be used for polishing.

In an embodiment according to the invention the ratio between the stiffness of the pressure member to the stiffness of the at least one intermediary plate is greater than 1.5, preferably greater than 5 and most preferably greater than 10.

The stiffness can for example be expressed by the Young's modulus or the Shore hardness. By providing the abovementioned ratio of the stiffness an efficient trade-off between the handling of the floor sanding device and the effective sanding pressure is achieved.

In an embodiment according to the invention the at least one pressure member comprises rubber.

Rubber has the advantage that it is relatively high stiffness and at the same time at least partially deformable. By using rubber an adequate sanding pressure is obtained at the location of the pressure members. Preferably the intermediary plate comprises a material with a lower stiffness, such as foam rubber. In an alternative embodiment the pressure members are made of plastic, such as polyvinyl chloride (PVC) and/or metals.

In an embodiment according to the invention the compartments are disc-shaped.

The compartments being disc-shaped achieve an effective sanding of the floor, especially when the drive provides a circular motion to the carrier plate.

In an embodiment according to the invention the intermediary plate comprises three compartments that are symmetrically distributed around a center point of the intermediary plate.

When the compartments are provided with pressure members, these pressure members provide more pressure to the floor than the intermediary plate and can thus be seen as the ‘legs’ of the floor sanding device. The advantage of having three compartments distributed symmetrically around a center point is that a stable floor sanding device is obtained, as the floor sanding device has three ‘legs’ to support it. In this way shaking of the floor sanding device is reduced.

In an embodiment according to the invention the floor sanding device is a planetary floor sanding device.

By providing a planetary floor sanding device the floor sanding device acquires an effective sanding ability.

In an embodiment according to the invention the intermediary plate is at least partially flexible.

Flexible in the context of the present invention means being able to deform when a force is applied and after the force has been removed being able to transform back into its original form. An advantage of the intermediary plate being at least partially flexible is that the floor sanding device acquires its easy handling and damage-reducing ability when confronted with irregularities on the floor.

In an embodiment according to the invention the floor sanding device further comprises a damping plate that is arranged between the carrier plate and the intermediary plate for partially dampening the sanding during use.

By providing a damping plate between the carrier plate and the intermediary plate the sanding pressure can be decreased. This has as its advantage that the sanding pressure can be further adjusted according to the required sanding pressure and/or depth. A further advantage of the damping plate is that the pressure members are further stabilized so they are aligned with the floor surface.

In an embodiment according to the invention the treatment plate comprises air holes.

During sanding of the floor dust is created under the treatment plate. The advantage of air holes in the treatment plate is that dust can be easily suctioned from under the treatment plate, thereby preventing damage to the floor. Alternatively, or additionally, the effectiveness of the treatment plate on the floor is increased, as the surface area of the treatment plate directly in contact with the floor is maximal. Another advantage of air holes is that excessive heat created during sanding can be removed, thereby cooling the floor sanding device.

Optionally, the pressure members are removed without replacement. Further, the plate can be rotated over an angle to position the one or more compartments over the air holes. For example, such embodiments can be advantageously used for polishing. Preferably, the design, shape and/or construction of the (group of) air holes and the pressure members are similar for providing an effective airstream and/or suctioning of dust.

In an embodiment according to the invention the air holes are distributed unevenly on the floor treatment plate.

By distributing the air holes unevenly the air holes can be grouped together, for example. This increases the effective surface area of the treatment plate, as at the location of the air holes there is a loss of sanding pressure.

In an embodiment according to the invention the air holes are distributed such that they are located in a different location than the at least one compartment of the treatment plate as seen in a direction perpendicular to a plane parallel to the floor.

As there is less sanding pressure at the locations where the compartments are not located as seen in a direction perpendicular to a plane parallel to the floor, dust created during sanding is collected at these locations. The locations where the compartments are not located function as a sort of vacuum and collect the dust. Thus placing the dust holes at these locations is advantageous as the majority of the dust is collected exactly at these locations. An effective dust removal under the treatment plate is hereby obtained. Another advantage of not positioning the dust holes at the location of the pressure members is that the chance of sanding grains being broken off from the treatment plate is reduced. In a preferred embodiment the air holes of the floor treatment plate are distributed in three groups, and wherein each of the three groups has a group center point, wherein the group center points are provided at 120° from each other around a treatment center point from the floor treatment plate.

In an embodiment according to the invention the intermediary plate comprises air holes, wherein the air holes of the intermediary plate are located at substantially the same location as the air holes in the treatment plate as seen in a direction perpendicular to a plane parallel to the floor.

The air holes provide the same advantages as for the treatment plate. Placing the air holes at substantially the same location as seen in a direction perpendicular to a plane parallel to the floor in relation to the treatment plate secures an effective transport of dust from under the treatment plate through the treatment plate to the intermediary plate.

In an embodiment according to the invention the carrier plate comprises air holes, wherein the air holes are located at substantially the same location as the air holes in the treatment plate and/or intermediary plate as seen in a direction perpendicular to a plane parallel to the floor.

The air holes provide the same advantages as for the treatment plate and/or intermediary plate. Placing the air holes at substantially the same location as seen in a direction perpendicular to a plane parallel to the floor in relation to the treatment plate secures an effective transport of dust from under the treatment plate through the treatment plate and intermediary plate to the carrier plate.

It is clear for the skilled person that instead of dust holes in the intermediary plate, damping plate and/or carrier plate it is alternatively possible to transport dust sideways through a dust channel. This dust channel can be provided in the intermediary plate, the damping or the carrier plate.

In an embodiment according to the invention the intermediary plate is attached to the carrier plate with a hook-and-loop fastener connection.

In the context of the present invention a hook-and-loop fastener may also relate to a Velcro-connection. A hook-and-loop fastener connection is advantageous as it makes the connection and removal of the intermediary plate to the carrier plate easy. This provides an easier handling of the floor sanding device.

In the present invention the carrier plate, the damping plate, the intermediary plate, the pressure members and the treatment plate could all be connected through hook-and-loop fasteners. Alternatively these elements could all be connected through a hard connection, such as screws, or via glue. Another possible connection is a clamping connection, for example between the pressure members and the intermediary plate. Any combination of the aforementioned connections is likewise possible.

The invention further relates to a floor treatment plate for use with a floor sanding device, wherein the floor treatment plate comprises air holes that are distributed unevenly over the floor treatment plate for providing cooling and/or suctioning of dust.

The uneven distribution has as its advantage that the air holes can be grouped together, for example. This increases the effective surface area of the treatment plate, as at the location of the air holes there is a loss of sanding pressure.

In an embodiment according to the invention the air holes of the floor treatment plate are distributed in three groups, and wherein each of the three groups has a group center point, wherein the group center points are provided at 120° from each other around a treatment center point from the floor treatment plate.

As there is less sanding pressure at the locations where the compartments are not located as seen in a direction perpendicular to a plane parallel to the floor, dust created during sanding is collected at these locations. The locations where the compartments are not located function as a sort of vacuum and collect the dust. Thus placing the dust holes at these locations is advantageous as the majority of the dust is collected exactly at these locations. In the embodiment wherein three compartment are positioned symmetrically around a center point, the abovementioned placement of the air holes is very advantageous. An effective dust removal under the treatment plate is hereby obtained.

The invention further relates to a method for sanding a floor, wherein the method comprises the steps of:

-   -   providing a floor sanding device according to the invention; and     -   sanding the floor with the floor sanding device.

The method has similar effects and advantages as described for the floor sanding device and the treatment plate.

In an embodiment according to the invention the method further comprises:

-   -   changing the at least one pressure member of the intermediary         plate.

This has as its further advantage that a broken and/or malfunctioning pressure member is easily replaced, thereby increasing the longevity of the intermediary plate and floor sanding device.

Further advantages, features and details of the invention are elucidated on the basis of preferred embodiments thereof, wherein reference is made to the accompanying drawings, in which:

FIG. 1 shows an example of a floor sanding device according to the invention;

FIG. 2A shows an example of a carrier plate according to the invention;

FIG. 2B shows an example of a damping plate according to the invention;

FIG. 2C shows an example of an intermediary plate according to the invention;

FIG. 2D shows an example of pressure members according to the invention;

FIG. 2E shows an example of a treatment plate according to the invention; and

FIG. 3 shows an example of a intermediary plate according to the invention.

Floor sanding device 2 (FIG. 1 ) comprises transport cart 4 that is connected with pivot connection 6 to housing 8. Housing 8 comprises top plate 10 whereon drive system 12 is provided. Drive system 12 comprises motor 14 that is connected to transmission 16. Via transmission 16 drive motor 14 is operatively coupled to carrier plate 20 that is provided under top plate 10. It is clear for the skilled person that instead of transport cart 4 use can be made of a floating floor sanding device.

In the illustrated embodiment floor sanding device further comprises dust container 27. Dust container 27 is via dust tube 28 connected to dust opening 30 that is provided on top plate 10. In this way dust collected during sanding of floor 3 can be easily stored in dust container 27.

Top plate 10 comprises water opening 15 that is connectable to a water supply for supplying water to floor sanding apparatus 2. Housing 8 of floor sanding device 2 further comprises, seen in a direction from top to bottom, damping plate 22, intermediary plate 24 and treatment plate 26. Carrier plate 20, damping plate 22, intermediary plate 24 and treatment plate 26 can be connected in various ways, for example with screws, with glue and/or with hook-and-loop fasteners, and are in use operatively connected to carrier plate 20. In this example at least the connection between damping plate 22 and intermediary plate 24 is provided by a hook-and-loop connection.

Carrier plate 120 (FIG. 2A), in this example made of metal, comprises dust holes 130. In the illustrated embodiment dust holes 130 are distributed unevenly over carrier plate 120, and are more specifically grouped symmetrically around center point 132 of carrier plate 120 in a rotational manner Dust holes 130 are divided in three triangular groups 130 a, 130 b and 130 c. Groups 130A, 130B and 130C are positioned such that one corner is pointing towards center point 132. Further provided on carrier plate 120 are connection holes 134. Connection holes 134 are configured to be operatively connected to motor 14 of drive system 12, such that carrier plate 20 can be given the desired movement. Instead of using connection holes 134 carrier plate 20 can also be connected to motor 14 in various other ways, for example with screws and/or glue.

Damping plate 222 (FIG. 2B) also comprises dust holes 230. Dust holes 230 are, when seen in a direction A that is in use substantially perpendicular to floor 3, positioned at the same location as dust holes 130. This achieves that dust created by sanding floor 3 can be effectively transported to dust container 27. Further provided in damping plate 222 are connection holes 234 for connecting damping plate 222 to carrier plate 120. Alternatively, damping plate 222 can also be connected to carrier plate 120 via a hook-and-loop connection. In this example damping plate 222 is substantially made of foam rubber. This achieves that the pressure provided by floor sanding apparatus 2 is reduced. This is advantageous if one wants reduce the depth of sanding, or when one wants to polish floor 3 instead of sanding it. A further advantage of the damping plate is that the pressure member is forced to be parallel to the floor.

Intermediary plate 324 (FIG. 2C) also comprises dust holes 330, provided at the same location as dust holes 230 and 130 as seen in direction A. Further provided in intermediary plate 324 are compartments 340 that are configured to receive pressure members 342 (FIG. 2D). In the illustrated embodiment, intermediary plate 324 comprises three compartments 340 such that three pressure members 342 can be placed therein.

In this exemplified embodiment pressure members 342 are substantially made of rubber, while intermediary plate 324 is substantially made of foam rubber. Therefore, the stiffness of pressure members 342 is higher than the stiffness of intermediary plate 324. In this exemplified embodiment the stiffness of pressure members is about three times as high as the stiffness of the foam rubber is, i.e. the Young's modulus of pressure members 342 is about three times as high as the Young's modulus of intermediary plate 324.

Pressure members 342 are replaceably provided in compartments 340, such that pressure members 342 can be replaced by elements having the same shape as pressure members 342 and having a different stiffness. For example, elements with the same material or at least material with the same stiffness as intermediary plate 324 can be placed in compartments 340. This realizes that floor sanding device 2 can easily apply different kinds of pressure on floor 3, thus realizing a very versatile floor sanding device 2. In an alternative embodiment it is also possible that compartments 340 are not complete openings in intermediary plate 324, but still have a small layer of intermediary plate 324 left, wherein the small layer is positioned near carrier plate 120. This gives pressure members 342 the ability to more easily move along with irregularities in floor 3, thereby reducing the risk of unwanted scratches in floor 3.

In an example it is possible to replace pressure members 342 with other pressure members. Alternatively it is possible to remove pressure members 342 without replacement, such that floor sanding device 2 can be used for polishing. Optionally it is possible to rotate treatment late 324 such that compartments 340 are located at the location of dust holes 230 and 430. In the illustrated embodiment this would amount to a rotation of about 60°. It is possible that compartments 330, pressure members 342 and groups 130A, 130B and 130C have a similar shape and/or design. In an example, compartments 330, pressure members 342 and groups 130A, 130B and 130C could all be substantially triangular-shaped, rectangular-shaped or disc-shaped. It will be understood that other shapes can also be envisaged according to the invention.

Treatment plate 426 (FIG. 2E) is also provided with dust holes 430, at the same location as dust holes 330, 230 and 130 as seen in direction A. Thereby an effective transport of dust from floor 3 to dust container 27 is made possible. Lower side 450 of treatment plate 426 is provided with an abrasive topping, such that floor 3 can be effectively sanded by floor sanding device 2.

It will be that alternative configurations of carrier plate 20, 120, damping plate 22, 222, intermediary plate 24, 324 and/or treatment plate 26, 426 can be designed and/or configured in different ways according to the present invention.

It is clear for the skilled person that dust holes 130 and 230 are not essential. It is also possible to transport dust from intermediary plate 324 in a sideways direction through a dust channel. This dust channel could for example be provided in damping plate 222, but is not limited thereto.

Through the pressure of pressure members 542 local pressure field 544 (FIG. 3 ) is created surrounding center point 532. In local pressure field 544 there is a substantially higher pressure provided to floor 2 when pressure members 442 have a higher stiffness than intermediary plate 426. As a consequence of local pressure field 544 dust 546 is being collected near locations with a lower pressure, in particular the location of groups 530 a, 530 b and 530 c. Groups 530 a, 530 b and 530 c have group center points 560 a, 560 b and 560 c respectively, which are positioned at angle α of 120° from each other around center point 532. Thus with the exemplified embodiment the location of where dust holes 530 are positioned function as a ‘vacuum’ and undesired dust 546 is easily removed. This increases the effectiveness of floor sanding device 2.

In an embodiment according to the invention floor sanding device 2 is brought into a to be sanded floor 2. Motor 14 then brings, through transmission 16, carrier plate 20 in movement. As treatment plate 26 is operatively coupled to carrier plate 20, treatment plate 26 will sand the floor. During sanding dust 546 is created and subsequently transported through dust holes 430, 330, 230 and 130 respectively, via dust tube 28 into dust container 27. After sanding floor 2, pressure members 342 can be removed from compartments 340 of intermediary plate 324. Afterwards elements that have the same or a similar stiffness as intermediary plate 324 can be placed in compartments 340, such that floor 2 can also be polished by floor sanding device 2.

The present invention is by no means limited to the above described preferred embodiments thereof. The rights sought are defined by the following claims within the scope of which many modifications can be envisaged. 

1. A floor sanding device, comprising: a carrier plate and a drive for driving the carrier plate; a treatment plate for treating a surface of a floor, wherein the treatment plate is operatively coupled to the carrier plate; and an intermediary plate that is arranged between the carrier plate and the treatment plate, wherein the intermediary plate comprises at least one compartment for receiving at least one pressure member for providing a higher local pressure.
 2. The floor sanding device according to claim 1, wherein the floor sanding device further comprises at least one pressure member that is configured for placement in the at least one compartment, wherein a stiffness of the at least one pressure member is higher than a stiffness of the intermediary plate.
 3. The floor sanding device according to claim 2, wherein the at least one pressure member is removably provided in the at least one compartment.
 4. The floor sanding device according to claim 2, wherein a ratio between the stiffness of the at least one pressure member to the stiffness of the intermediary plate is greater than 1.5, preferably greater than 5 and most preferably greater than
 10. 5. The floor sanding device according to claim 2, wherein the at least one pressure member comprises rubber.
 6. The floor sanding device according to claim 1, wherein the compartments are disc-shaped.
 7. The floor sanding device according to claim 1, wherein the intermediary plate comprises three compartments that are symmetrically distributed around a center point of the intermediary plate.
 8. The floor sanding device according to claim 1, wherein the floor sanding device is a planetary floor sanding device.
 9. The floor sanding device according to claim 1, wherein the intermediary plate is at least partially flexible.
 10. The floor sanding device according to claim 1, further comprising a damping plate that is arranged between the carrier plate and the intermediary plate for partially dampening the sanding during use.
 11. The floor sanding device according to claim 1, wherein the treatment plate comprises air holes.
 12. The floor sanding device according to claim 11, wherein the air holes are distributed unevenly on the floor treatment plate.
 13. The floor sanding device according to claim 12, wherein the air holes are distributed such that they are located in a different location than the at least one compartment of the treatment plate as seen in a direction perpendicular to a plane parallel to the floor.
 14. The floor sanding device according to claim 11, wherein the intermediary plate comprises air holes, wherein the air holes are located at substantially the same location as the air holes in the treatment plate as seen in a direction perpendicular to a plane parallel to the floor.
 15. The floor sanding device according to claim 11, wherein the carrier plate comprises air holes, wherein the air holes are located at substantially the same location as the air holes in the treatment plate and/or intermediary plate as seen in a direction perpendicular to a plane parallel to the floor.
 16. The floor sanding device according to claim 1, wherein the intermediary plate is attached to the carrier plate with a hook-and-loop fastener connection.
 17. The floor treatment plate for use with a floor sanding device according to claim 1, the floor treatment plate comprising air holes that are distributed unevenly over the floor treatment plate for providing cooling and/or suctioning of dust.
 18. The floor treatment plate according to claim 17, wherein the air holes are distributed in three groups, and wherein each of the three groups has a group center point, wherein the group center points are provided at 120° from each other around a treatment center point from the floor treatment plate.
 19. A method for sanding a floor, comprising: providing a floor sanding device according to claim 1; and sanding the floor with the floor sanding device.
 20. The method for sanding a floor of claim 19, further comprising: changing the at least one pressure member from the intermediary plate. 